28/09/05 MAN-044 /A
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OVERHAUL MANUAL
28/09/05 MAN-044 /A
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INDEX
Page
1. - PARILLA X30 125cc RL – TaG ENGINE DISASSEMBLY 1
2. - CRANKSHAFT DISASSEMBLY/ ASSEMBLY 10
2.1- CRANKSHAFT DISASSEMBLY 10
2.2- CRANKSHAFT ASSEMBLY 12
3. - PARILLA X30 125cc RL – TaG ENGINE ASSEMBLY 15
ATTACHMENTS
- FASTENER TORQUE VALUES
- CROSS PATTERN LOCKING ORDER ON CRANKCASE
- MAIN PRESCRIPTIONS
- CON-ROD BIG AND SMALL END BEARING TOLERANCES
- GEAR INSTALLATION - RECOMMENDATIONS
- LIST OF OVERHAUL TOOLS
- Table for wear evaluation on Bearings/ Halfcrankshafts
- BENCH ENGINE FIXING TOOL – Drawing
MAN-044/A
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1 – X30 125cc RL – TaG ENGINE DISASSEMBLY
OPERATIONS PICTURES
1.
DISCHARGE OIL FROM THE ENGINE
- UNSCREW THE OIL LEVEL PLUG
(see Fig.1).
(14mm socket wrench)
- TILT THE ENGINE TO DISCHARGE OIL
(see Fig.2).
2.
FIX THE ENGINE ON THE BENCH VICE
- SCREW ON N°2 SCREWS M8x60 ON THE
CRANKCASE
BENCH TOOL (see attached drawing )
3.
REMOVE THE EXHAUST HEADER
- UNSCREW N°2 NUTS M8 (see Fig. 3).
(13mm SOCKET WRENCH)
- REMOVE N°2 WASHERS
- REMOVE THE EXHAUST GASKET
Fi
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Fi
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Fig.3
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4.
REMOVE THE IGNITION
- REMOVE THE STATOR
UNSCREW N°4 ALLEN SCREWS M5x25 (see
Fig.4)
(4mm ALLEN WRENCH - T TYPE)
- REMOVE SPARKPLUG AND INSTALL THE
THE PISTON FITTING (P.N. 10271) TO
PREVENT THE CRANKSHAFT FROM
TURNING (see Fig.5).
- REMOVE THE NUT M10 AND WASHER
(see Fig.6).
(17mm SOCKET WRENCH)
- EXTRACT THE ROTOR (see Fig.7).
(USE A SCREWDRIVER IF NECESSARY)
REMOVE KEY FROM SHAFT
Fig.4
Fig.5
Fig.6
Fig.7
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5.
REMOVE THE GEAR BOX COVER
- UNSCREW N°7 ALLEN SCREWS M6x16
(see Fig.8).
(5mm ALLEN WRENCH - T TYPE)
- REMOVE COVER AND WASHER
(USE A PLASTIC MALLET IF NECESSARY)
(see Fig.9).
6.
REMOVE GEARS
- REMOVE RETAINING RINGS FROM THE
CRANKSHAFT AND BALANCE SHAFT
(see Fig.10).
(PLIERS FOR RETAINING RINGS)
- REMOVE GEAR ON THE CRANKSHAFT
(see Fig.11).
ATTENTION:
MARK THE GEAR FOR IDENTIFICATION
WHEN REASSEMBLING
NOTE:
IN THE ENGINES MNUFACTURED AFTER
SEPTEMBER ’05, THE FIXING OF THE GEAR
ON THE CRANKSHAFT IS MADE BY A
SPACER WITH AN “OR” WHICH IS PUSHED
AGAINST GEAR BY THE IGNITION ROTOR
(see drawing).
Fig.8
Fig.9
Fig.10
Fig.11
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- REMOVE GEAR FROM THE BALANCE
SHAFT
(see Fig.12).
(USE A SCREWDRIVER IF NECESSARY) .
7.
REMOVE ELECTRIC STARTER
- UNSCREW N°2 ALLEN SCREWS M6x35
(see Fig.13).
( 5mm ALLEN WRENCH – T TYPE )
- REMOVE STARTER (see Fig.14).
NOTE:
IN THE ENGINES MNUFACTURED AFTER
SEPTEMBER ’05, THE STARTER CAN ALSO
BE REMOVED WITHOUT TAKING AWAY
THE GEARS COVER BUT SIMPLY BY
REMOVING THE CLAMP OF THE COVER
(see drawing).
8.
REMOVE CLUTCH
- DISCONNECT THE GROUND CABLE FROM
THE CRANKCASE
UNSCREW THE ALLEN SCREW M6x12
(see Fig.15).
(5mm ALLEN WRENCH-T TYPE)
Fig.12
Fig.13
Fig.14
Fig.15
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- REMOVE CLUTCH COVER
UNSCREW N°3 ALLEN SCREWS M6x25
(see Fig. 16).
(5mm ALLEN WRENCH – T TYPE)
- REMOVE THE LOCKING NUT M10 FROM
CLUTCH DRUM (see Fig.17).
(17mm SOCKET WRENCH )
NOTE:
MAKE SURE THAT THE PISTON STOP TOOL
IS INSTALLED (P.N. 10271)
- REMOVE OUTER WASHER, CLUTCH
DRUM, ROLLER CAGE AND INNER
WASHER
- REMOVE THE PISTON STOP TOOL
AND WITH THE CLUTCH LOCKING
WRENCH (P.N. 10270), REMOVE THE
LOCKING NUT M20 FROM CLUTCH BODY
(see Fig.18).
( 30 mm HEXAGON RING WRENCH)
ATTENTION:
TURN CLOCKWISE AS NUT HAS LEFT
THREAD.
- REMOVE CLUTCH BODY AND STARTING
RING FROM THE CRANKSHAFT WITH THE
CLUTCH DISASSEMBLY TOOL
(P.N. 10272-C) (see Fig.19).
(12mm ALLEN WRENCH
(27mm WRENCH)
Fig.16
Fig.17
Fig.18
Fig.19
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- REMOVE STARTING RING
FROM CLUTCH BODY
UNSCREW N°3 SCREWS M6x12 (see
Fig.20).
(10mm SOCKET WRENCH)
9.
REMOVE STARTER COUNTERSHAFT
- REMOVE STARTER COUNTERSHAFT
COVER
UNSCREW N°3 ALLEN SCREWS M6x25 (see
Fig.21).
( 5mm ALLEN WRENCH – T TYPE )
- EXTRACT STARTER COUNTERSHAFT
(see Fig.22).
10.
REMOVE CARB. INLET CONVEYOR
- UNSCREW N°4 ALLEN SCREWS M6x25
(see Fig.23).
(5mm ALLEN WRENCH –T TYPE )
- REMOVE OUTER GASKET FROM
CONVEYOR
Fig.20
Fig.21
Fig.22
Fig.23
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- REMOVE REED GROUP
(see Fig.24).
- REMOVE INNER WASHER FROM
REED GROUP
11.
REMOVE CYLINDER HEAD
- UNLOOSE N°4 NUTS M8 BY HALF TURN
(CROSS PATTERN DISASSEMBLY),
REMOVE NUTS
(see Fig.25).
( 13mm HEXAGON RING WRENCH)
- REMOVE WASHERS
12.
REMOVE CYLINDER
(see Fig.26).
- REMOVE CYLINDER BASE GASKET
13.
REMOVE PISTON
- REMOVE CIRCLIPS FROM PISTON
(see Fig.27).
(SCREWDRIVER WITH ROUND EDGES)
ATTENTION:
DO NOT SCRATCH PISTON AND CIRCLIP
SEATS.
Fig.24
Fig.25
Fig.26
Fig.27
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- REMOVE PISTON PIN WITH SPECIAL
PISTON PUNCH (P.N. 10200)
(see Fig.28).
- REMOVE PISTON
- REMOVE ROLLER CAGE
14.
OPEN CRANKCASE
- UNSCREW N°10 ALLEN SCREWS M6x45
(see Fig.29).
(5mm ALLEN WRENCH – T TYPE)
- OPEN CRANKCASE WITH A PLASTIC
MALLET
(see Fig.30).
(PREVENT THE CRANKSHAFT FROM
FALLING)
15.
REMOVE CRANKSHAFT AND BALANCE
SHAFT
(see Fig.31).
Fig.28
Fig.29
Fig.30
Fig.31
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16.
REMOVE OIL SEALS
(USE A SCREWDRIVER) (see Fig.32).
17.
REMOVE BEARINGS (IF NECESSARY)
CHECK THE INNER DIAMETER OF
BEARINGS, ON DIFFERENT POINTS.
REFER TO THE ATTACHED TABLE TO
CHECK BEARING WEAR STATUS.
- REMOVE BEARINGS FROM CRANKSHAFT
WITH THE SPECIAL TOOL
(P.N. 10291) (see Fig.33).
REMOVE BEARING SPACERS
(0.10 / 0.15)
- REMOVE BALANCE SHAFT OUTER
BEARING (GEAR SIDE)
UNSCREW THE BEARING RETAINING
SCREW M5x10
(see Fig.34).
(4mm ALLEN WRENCH – T TYPE)
REMOVE BEARING WITH SPECIAL TOOL
(P.N. 10293)
(see Fig.35).
Fig.32
Fig.33
Fig.34
Fig.35
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- REMOVE INTERNAL BEARING FROM
BALANCE SHAFT
HEAT BEARING SEAT EXTERNALLY
WITH A BLOWPIPE
(see Fig.36).
ATTENTION:
CAREFULLY DEGREASE THE SURFACES
NEAR THE BEARING BEFORE HEATING
ONCE THE PROPER TEMPERATURE IS
REACHED, REMOVE BEARING KNOCKING
THE HALFCRANKCASE ON THE WORKING
BENCH.
2 – CRANKSHAFT ASSEMBLY/DISASSEMBLY
ATTENTION:
THE ASSEMBLY/DISASSEMBLY OPERATIONS ON THE ENGINE CRANKSHAFT, MUST BE
PERFORMED ONLY BY AN AUTHORIZED SERVICE CENTER USING THE SPECIALLY DESIGNED
TOOLS. USE OF UNFITTED TOOLS OR OPERATIONS PERFORMED BY UNSKILLED PERSONNEL
MAY DAMAGE THE CRANKSHAFT BEYOND REPAIR.
DESCRIPTION P.N.
CRANKSHAFT ASSEMBLY KIT 10110B-C
CRANKPIN BUSH (INCLUDED IN 10110B-C) 10150A
CRANKSHAFT DISASSEMBLY KIT INCLUDES: 10100A-C2
CRANKSHAFT SUPPORT 10100
CRANKSHAFT PLATE 10104A
CRANKSHAFT INSERT 10106
CRANKPIN PUSHER 10107
2.1 – CRANKSHAFT DISASSEMBLY
OPERATIONS PICTURES
1.
PLACE THE DISASSEMBLY TOOL
(P.N. 10100A-C2) UNDER THE PRESS
(PRESS 5 MeT).
2.
PLACE THE CRANSHAFT IN THE TOOL
BY INSERTING THE CRANKSHAFT PLATE
(P.N. 10104A) BETWEEN THE CRANKSHAFT
HALVES (see Fig.1).
Fi
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Fig.36
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3.
INSERT THE CRANKSHAFT INSERT
(P.N. 10106) AND USING THE CRANKPIN
PUSHER ( P.N. 10107 ) PRESS THE
CRANKPIN OUT
(vedi Fig.2).
4.
DISASSEMBLE THE COMPLETE CON-ROD
WITH WASHERS.
REPEAT THE OPERATIONS TO EXTRACT
THE CRANKPIN FROM THE OTHER HALF
CRANKSHAFT (see Fig.3).
BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE
a) CHECK STATUS OF CON-ROD (TOP
AND BOTTOM).
IF OVALIZATION EXCEEDS 0.01mm,
REPLACE CON-ROD.
- O.O1 CENTESIMAL MICROMETER (21/50)
- 0.001 BORE GAUGE WITH CHECK RING Ø26 AND Ø18
b) CHECK STATUS OF CRANKPIN
VISUAL CHECK – REPLACE IF
NECESSARY
REPLACE AFTER 30 WORKING HRS.
c) CHECK STATUS OF CAGE (BIG END)
VISUAL CHECK – REPLACE IF
NECESSARY
REPLACE AFTER 30 WORKING HRS.
d) CHECK STATUS OF CRANKSHAFT
HALVES.
CHECK BEARING SEATS IN
DIFFERENT POINTS.
REFER TO THE ATTACHED TABLE TO
CHECK THE WEAR STATUS OF THE
CRANKSHAFT HALVES.
e) CHECK STATUS OF SILVER SHIMS
VISUAL CHECK – REPLACE IF
NECESSARY .
FOLLOW ATTACHED TABLE FOR MAX. MATCHING PLAY
Fi
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Fi
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2.2 – CRANKSHAFT ASSEMBLY OPERATIONS
OPERATIONS PICTURES
1. PLACE THE CRANKSHAFT ASSEMBLY
TOOL (P.N. 10110B-C) UNDER THE PRESS,
VERTICALLY (PRESS 5 MeT).
2. PLACE THE CRANKSHAFT TOOL INTO THE
ASSEMBLY TOOL.
3. OIL CRANKPIN HOLE ON CRANKSHAFT
HALF.
4.
PLACE CRANKPIN WITH CRANKPIN BUSH
(P.N. 10150A) ON CRANKSHAFT HALF (see
Fig.1).
5.
BRING UPPER PLATE OF TOOL IN
CONTACT WITH CRANKPIN (see Fig.2).
6.
PROGRESSIVELY PRESS UNTIL CRANKPIN
IS COMPLETELY DRIVEN IN
(see Fig.3).
Fi
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Fi
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Fi
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7.
EXTRACT BUSH FROM CRANKPIN AND
PUT TOOL IN HORIZONTAL POSITION
(see.Fig.4).
8.
OIL CRANKPIN AND INSTALL:
-SILVER SHIM
-CON-ROD WITH ROLLER CAGE
-SILVER SHIM
(see Fig.5).
ATTENTION:
ROLLERS ARE FREE IN THE CAGE.
PREVENT THEM FROM FALLING,
WHEN INSERTING THE CAGE ON THE
CRANKPIN.
9.
PLACE THE SECOND CRANKSHAFT IN
THE SEAT OF THE COUNTERPLATE
(see Fig.6).
10.
BRING THE 2 PLATES CLOSE UNTIL THE
TOOL IS HAND PRESSED
(see Fig.7).
Fi
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Fi
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Fi
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Fi
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11. OIL CRANKPIN AND CRANKPIN HOLE ON
CRANKSHAFT HALF.
12.
PUT TOOL IN VERTICAL POSITION (see
Fig.8).
13. PROGRESSIVELY PRESS THE TWO
CRANKSHAFT HALVES TOGETHER.
14. OPEN THE TOOL, PUT IT IN HORIZONTAL
POSITION AND EXTRACT CRANKSHAFT.
15.
CHECK THE AXIAL PLAY OF THE CON-ROD
(see Fig. 9).
IT MUST BE MIN. 0.3mm / MAX. 0.7mm.
IF PLAY IS HIGHER OR LOWER, REBUILD
THE CRANKSHAFT.
AFTER ASSEMBLING THE CRANKSHAFT, IT MUST BE ALIGNED. OTHERWISE EXCESSIVE
VIBRATIONS, HARD STARTING OR POOR ACCELERATION WILL RESULT.
a.
PLACE THE CRANKSHAFT BETWEEN THE
CENTERS, WITH DIAL INDICATORS
READING ON FRONT AND REAR BEARING
JOURNALS
(see Fig.10).
(CENTERS WITH CENTESIMAL DIAL
GAUGES AND COPPER HAMMER FOR
ALIGNMENT).
Fi
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Fi
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Fi
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b. ROTATE CRANKSHAFT AND LOOK AT
DEFLECTION OF GAUGE NEEDLES
THE DEFLECTION MUST BE, AFTER
CENTERING, MAX. 0.01mm
(see drawing).
c.
ADJUST ALIGNMENT WITH A COPPER
HAMMER, IF NECESSARY
(see Fig.11).
3 –X30 125cc RL – TaG ENGINE ASSEMBLY
BEFORE REASSEMBLING, WASH ALL PARTS WITH KEROSENE
OPERATIONS PICTURES
1.
INSTALLING BEARINGS
- PLACE THE CRANKCASE HALVES UNDER
THE PRESS.
- INSERT BEARING SHIMS
(AVAILABLE SIZES 0.10 / 0.15 / 0.20)
(see Fig.1).
Fi
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Fi
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- INSERT CRANKSHAFT BEARINGS; BALLS
TO BE ON UPPER SIDE VISIBLE DURING THE
ASSEMBLY
(see Fig. 2).
OIL BEARINGS AND BEARING SEATS
OUTSIDE.
USE TOOL TO INSERT THE BEARINGS
(P.N. 10290)
(see Fig.3).
- INSTALL INNER BALANCE SHAFT
BEARING; BEARING BALLS TO BE ON
UPPER SIDE.
(OIL BEARING BALLS BEFORE
INSTALLATION) .
OIL BEARINGS AND HALFCRANKCASE
SEATS.
USE THE SPECIAL TOOL TO ASSEMBLE
(P.N. 10292) BEARINGS
(see Fig.4).
- INSTALL OUTER BALANCE SHAFT
BEARING (GEAR SIDE); BEARING BALLS
TO BE ON UPPER SIDE.
OIL BEARINGS AND HALFCRANKCASE
SEATS .
USE SPECIAL TOOL (P.N. 10293)
TO INSERT BEARING (see Fig.5).
Fi
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Fi
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Fi
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Fi
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Fi
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- INSTALL THE BEARING RETAINING.
SCREW M5x10 (see Fig.6). Allen.
TORQUE AT A 6 ÷ 8 Nm (50 ÷ 70 in-lb).
(4mm ALLEN WRENCH – T TYPE)
2.
CRANKCASE ASSEMBLY
- INSERT CRANKSHAFT AFTER OILING THE
CRANKSHAFT SEAT IN THE CRANKCASE
AND THE BEARING BALLS.
THE CRANKSHAFT MUST BE IN SAME
POSITION AS IN ORIGINAL INSTALLATION
(see Fig.7).
- ASSEMBLE CRANKCASE HALVES
N°10 ALLEN SCREWS M6x45 (see Fig.8).
(CROSS PATTERN ASSEMBLY – SEE
ATTACHED DRAWING).
TORQUE AT 8÷10 Nm (70 ÷ 90 in-lb)
(5mm ALLEN WRENCH – T TYPE)
ATTENTION:
AS FIRST STEP ASSEMBLE CRANKCASE
WITH 4 SCREWS AND CHECK CRANKSHAFT
AXIAL PLAY TO BE 0.20 ±0.05mm.
IF PLAY IS LOWER OR HIGHER
DISASSEMBLE CRANKCASE, EXTRACT
BEARINGS AND USE DIFFERENT STEEL
SHIMS (0.10/0.15/0.20) TO RECOVER PLAY.
SHIMS MUST BE EQUALLY POSITIONED (see
Fig. 9).
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Fi
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BEFORE FINAL ASSEMBLING OF
CRANKCASE HALVES APPLY FLUID GASKET
(Motorseal or equivalent) ON CRANKCASE
HALVES.
CLEAN EVENTUAL EXCESS OF PRODUCT
(see Fig.10).
- OIL CRANKSHAFT AND BEARING BALLS
SEATS BEFORE ASSEMBLING.
(see Fig.11).
- INSERT THE CRANKSHAFT AND BALANCE
SHAFT.
CLOSE THE CRANKCASE HALVES
(see Fig.12).
3.
INSTALLING SEALS
- APPLY SPECIAL LUBRICANT ON SEAL LIPS
(see Fig.13).
ATTENTION:
WHEN INSTALLING NEW SEALS, TURNING
THE CRANKSHAFT SHOULD RESULT MORE
DIFFICULT, BUT THIS IS NORMAL.
Fi
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Fi
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Fi
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Fi
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